Collapsible chair assembly

ABSTRACT

Systems and methods for a collapsible chair assembly are described. Systems and methods may include a seat component including a first seat support arc, a second seat support arc, and one or more seat slats spanning the first seat support arc and the second seat support arc; and a backrest component including at least one first support, at least one second support, a first backrest support arc, a second backrest support arc, and one or more backrest slats spanning the first backrest support arc and the second backrest support arc. Optionally, one or more holes may be found in at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc. The seat component may pass through an opening created by the at least one first support and the at least one second support.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 61/942,369, filed Feb. 20, 2014; the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to systems and methods for chairs, and, more specifically, to systems and methods for collapsible chair assemblies.

BACKGROUND OF THE INVENTION

A wide variety of folding or collapsible chairs have been developed. These include metal or plastic folding chairs for use in halls or auditoriums and beach or yard chairs often having plastic straps across an aluminum tube frame or comprising canvas extending across wood frames. Others are made in two parts, a back portion and a seat portion that can be combined for seating and separated for storage and transport.

Such chairs should be comfortable, light in weight, sturdy and easily moved between collapsed storage and carrying position and an erected position for use.

There is a continuing need for improved chairs that can be assembled and disassembled, that are comfortable, sturdy, lightweight and that can be easily assembled and, when disassembled can be brought together in a compact, easily stored and transported, package that will not accidentally come apart when carried. Ideally, the angle between seat and back should be variable for optimum comfort. Needs exist for improved systems and methods for chair assemblies with improved comfort and lighter weight.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detailed description serve to explain the principles of the invention. In the drawings:

FIG. 1 is a perspective view of a collapsible chair assembly, according to one embodiment.

FIG. 2 is a top view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 3 is a bottom view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 4 is a front view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 5 is a back view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 6 is a left side view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 7 is a right side view of the collapsible chair assembly of FIG. 1, according to one embodiment.

FIG. 8 shows an intersection of the backrest component and the seat component, according to one embodiment.

FIG. 9 is a perspective view of the collapsible chair assembly of FIG. 1 in a nested position, according to one embodiment.

FIGS. 10-10E are side views of exemplary hole configurations and/or no hole configurations, according to certain embodiments.

FIGS. 11A-11F are perspective views showing exemplary seating positions, according to certain embodiments.

FIG. 12 is a perspective view showing multiple chair assemblies coupled to form a table base, according to one embodiment.

FIG. 13 is a perspective view of an exemplary chair assembly with rocker arcs and arm rests, according to certain embodiments.

FIG. 14 is a detail of an exemplary arm rest in an upright position, according to certain embodiments.

FIG. 15 is a perspective view of an exemplary clip, according to certain embodiments.

FIG. 16 is a perspective view of an exemplary stand-off, according to certain embodiments.

FIGS. 17A-17B are views of an exemplary slat, according to a certain embodiments.

FIGS. 18A-18B are views of an exemplary rail with a groove, according to certain embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Systems and methods are described for collapsible chair assemblies, methods of assembling and disassembling collapsible chair assemblies, and methods of manufacture of collapsible chair assemblies.

FIG. 1 is a perspective view of a collapsible chair assembly, according to one embodiment. Chair assemblies may be made of any suitable substance. In certain embodiments, the chair assembly may be made completely or substantially out of wood, bamboo, or other natural materials. In other embodiments, the chair assembly may be made completely or substantially out of plastic, metal, etc. In other embodiments, combinations of wood, bamboo, other natural materials, metal, plastic, etc. may be used. In certain embodiments, wood and plastic pieces may be used in combination. Fasteners may be used. Hardware may be used to couple the various components together. Hardware may include screws, nails, bolts, dovetails, dowels, etc. Adhesives may also be used to couple various components together. Alternatively, certain parts can be molded together in the manufacturing process.

FIGS. 2-7 show various views of the chair assembly of FIG. 1. FIG. 2 is a top view of the collapsible chair assembly of FIG. 1. FIG. 3 is a bottom view of the collapsible chair assembly of FIG. 1. FIG. 4 is a front view of the collapsible chair assembly of FIG. 1. FIG. 5 is a back view of the collapsible chair assembly of FIG. 1. FIG. 6 is a left side view of the collapsible chair assembly of FIG. 1. FIG. 7 is a right side view of the collapsible chair assembly of FIG. 1.

A chair assembly 101 may include two main elements, a seat component 103 and a backrest component 105.

The seat component 103 may have one or more seat slats 107 stretching from a first seat support arc 109 to a second seat support arc 111. The one or more seat slats 107 may be coupled to the first seat support arc 109 and the second seat support arc 111 by fasteners. In certain embodiments, the one or more seat slats 107 may be coupled to the first seat support arc 109 and the second seat support arc 111 by one or more capture slots, such as sockets into which the one or more seat slats 107 may be inserted into the first seat support arc 109 and the second seat support arc 111. One or more capture slots may be used with one or more features of the chair assembly 101, including elements made of plastic. The one or more capture slots may eliminate the need for fasteners, such as screws. The one or more capture slots may provide for quicker assembly of the chair.

The one or more slats 107 can be made of different materials or dimensioned so that they are more or less stiff when holding the weight of a user. The one or more slots 107 may be grooved or have openings/holes to increase air circulation and/or flexibility. Alternatively, the one or more slots 107 may be solid.

The one or more seat slats 107 can be of the same dimensions or different dimensions relative to one another. In certain embodiments, the seat slats may be from approximately 10″ L to approximately 72″ L, from approximately 1″ W to approximately 8″ W, and from approximately ⅛″ H to approximately 1″ H, more preferable from approximately 12″ L to approximately 36″ L, from approximately 1.5″ W to approximately 6″ W, and from approximately ⅛″ H to approximately ¾″ H, and most preferably from approximately 16″ L to approximately 24″ L, from approximately 2″ W to approximately 2.5″ W, and from approximately ⅜″ H to approximately ½″ H. The seat component 103 may include one or more seat slats 107, preferably between approximately 1 and 20 seat slats, more preferably between 2 and 10 seat slats, and most preferably between 3 and 6 seat slats. The seat slats may be flat or may have an arc. The arc may conform to an arc of the first seat support arc 109 and the second seat support arc 111. The one or more seat slats 107 may have gaps between them or may be abutted against one another. In certain embodiments, the gap between the seat slats may be from approximately 0″ to approximately 6″, more preferably approximately 0.5″ to approximately 3″, and more preferably from approximately 0.75″ to approximately 1.5″. By using additional arc members, the seat can be designed to hold two, three, four, or more individuals. Thus, the seat can also function as a type of bench, such as a park bench. In certain embodiments, the chair/sections with arc members may be modular so that any number of seating portions can be combined together to make various width chairs/benches. Multiple arcs, such as 3 or 4 arcs, may be connected for various seating arrangements.

The seat component 103 may have the one or more seat slats 107 disposed on part or all of the first seat support arc 109 and the second seat support arc 111. In certain embodiments, the one or more seat slats 107 are disposed on approximately half of the first seat support arc 109 and the second seat support arc 111. The one or more seat slats 107 may be disposed on one side of the first seat support arc 109 and the second seat support arc 111 or both sides. For example, the one or more seat slats 107 may be located on a “top” surface of the first seat support arc 109 and the second seat support arc 111 where a user would sit to form a seat.

The first seat support arc 109 and the second seat support arc 111 may have an arc of a specified dimension. The arc may be from approximately 2″ deflection from straight in an approximately 38″ length to approximately 6″ deflection from straight in an approximately 38″ length, more preferably from approximately 2.5″ deflection from straight in an approximately 38″ length to approximately 5″ deflection from straight in an approximately 38″ length, and most preferably approximately 3″ deflection from straight in an approximately 38″ length. Deflections are measured to an inside diameter/surface of arc members. The increased arc may improve comfort of the chair assembly.

The ends of the first seat support arc 109 and the second seat support arc 111 may have various shapes, such as, but not limited to, square, rounded, etc.

The backrest component 105 may have one or more backrest slats 113 stretching from a first backrest support arc 115 to a second backrest support arc 117. The one or more backrest slats 113 may be coupled to the first backrest support arc 115 and the second backrest support arc 117 by fasteners or inserted into capture slots, such as sockets. In certain embodiments, the one or more backrest slats 113 may be coupled to the first backrest support arc 115 to a second backrest support arc 117 by one or more capture slots, such as sockets into which the one or more backrest slats 113 may be inserted into the first backrest support arc 115 to a second backrest support arc 117.

The one or more backrest slats 113 may vary in width. For example, the upper slats may be wider than the lower slats. Alternate patterns of wider and narrower slats may be used.

The one or more backrest slats 113 can be of the same dimensions or different dimensions relative to one another. In certain embodiments, the backrest slats may be from approximately 14″ L to approximately 72″ L, from approximately 1″ W to approximately 8″ W, and from approximately ⅛″ H to approximately 1″ H, more preferable from approximately 16″ L to approximately 36″ L, from approximately 1.5″ W to approximately 6″ W, and from approximately ⅛″ H to approximately ¾″ H, and most preferably from approximately 20″ L to approximately 26″ L, from approximately 2″ W to approximately 2.5″ W, and from approximately 0.75″ H to approximately 1.5″ H. The backrest component 105 may include one or more backrest slats 113, preferably between approximately 1 and 20 backrest slats, more preferably between 2 and 10 backrest slats, and most preferably between 3 and 6 backrest slats. The backrest slats may be flat or may have an arc. The arc may conform to an arc of the first backrest support arc 115 and the second backrest support arc 117. The one or more backrest slats 113 may have gaps between them or may be abutted against one another. In certain embodiments, the gap between the backrest slats may be from 0″ to approximately 6″, more preferably approximately 0.5″ to approximately 3″, and more preferably from approximately 1″ to approximately 2″. In certain embodiments, the one or more backrest slats 113 may be wider or narrower than the one or more seat slats 107.

The backrest component 105 may have the one or more backrest slats 113 disposed on part or all of the first backrest support arc 115 and the second backrest support arc 117. In certain embodiments, the one or more seat slats 113 are disposed on approximately half of the first backrest support arc 115 and the second backrest support arc 117. The one or more backrest slats 113 may be disposed on one side of the first backrest support arc 115 and the second backrest support arc 117 or both sides. For example, the one or more backrest slats 113 may be located on a “top” surface (concave side) of the first backrest support arc 115 and the second backrest support arc 117 where a user would lean on as a backrest.

The first backrest support arc 115 and the second backrest support arc 117 may have an arc of a specified dimension. The arc may be from approximately 2″ deflection from straight in an approximately 42″ length to approximately 6″ deflection from straight in an approximately 42″ length, more preferably from approximately 3″ deflection from straight in an approximately 42″ length to approximately 5″ deflection from straight in an approximately 42″ length, and most preferably approximately 4″ deflection from straight in an approximately 42″ length.

The ends of the first backrest support arc 115 and the second backrest support arc 117 may have various shapes, such as, but not limited to, square, rounded, etc.

One or more holes, slots, or openings 118 may be provided in the first seat support arc 109 and the second seat support arc 111 and/or the first backrest support arc 115 and the second backrest support arc 117. The one or more holes or openings 118 are described below.

FIG. 8 shows an intersection of the backrest component 105 and the seat component 103 in one embodiment. The backrest component 105 may also have supports 119, 120, 121, 122 for securing the seat component 103 in an assembled position. Additional supports may also be included to provide for additional seating positions. The supports 119, 120, 121, 122 may be shaped and/or angled to securely hold the seat component 103 relative to the backrest component 105 in an assembled position.

The first support 119 may span the first backrest support arc 115 and the second backrest support arc 117. The first support 119 preferably is located on the same side (concave side) of the backrest component 105 as the one or more backrest supports 113. The first support 119 may be more than one support, such that a series of supports are located on the same side of the backrest component 105 as the one or more backrest slats 113. This may provide alternate seat heights and/or angles. The first support 119 may have dimensions from approximately 10″ L to approximately 72″ L, from approximately 1″ W to approximately 8″ W, and from approximately ⅛″ H to approximately 1″ H, more preferable from approximately 12″ L to approximately 36″ L, from approximately 1.5″ W to approximately 6″ W, and from approximately ⅛″ H to approximately ¾″ H, and most preferably from approximately 16″ L to approximately 24″ L, from approximately 1.75″ W to approximately 2.5″ W, and from approximately 0.5″ H to approximately 0.75″ H. An optional supplementary first support 120 may be located on the same side (concave side) as the first support 119. The supplementary first support 120 may have similar dimensions as the first support 119. The first support 119 and the supplementary first support 120 may be angled or grooved to provide specific seating positions. The profile of one or both the first supports 119, 120 may be rounded, squared-off, angled, etc. In certain embodiments, the supplementary first support 120 may be distal relative to the one or more backrest slats 113 when compared with the first support 119. Additional supports may be provided along the length of the first backrest support arc 115 and the second backrest support arc 117. The seat component 103 may pass between the one or more backrest slats 113 and one or more of the first supports 119, 120, or between one or more of the first supports 119, 120.

The second support 121 may span the first backrest support arc 115 and the second backrest support arc 117. The second support 121 is preferably located on the opposite side (convex side) of the backrest component 105 as the one or more backrest slats 113 and the first support 119. The second support 121 may be more than one support, such that a series of supports are located on the opposite side of the backrest component 105 as the one or more backrest slats 113. This may provide alternate seat heights and/or angles. The second support 121 may have dimensions from approximately 14″ L to approximately 72″ L, from approximately 1″ W to approximately 8″ W, and from approximately ⅛″ H to approximately 1″ H, more preferable from approximately 16″ L to approximately 36″ L, from approximately 1.5″ W to approximately 6″ W, and from approximately ⅛″ H to approximately ¾″ H, and most preferably from approximately 20″ L to approximately 26″ L, from approximately 1.75″ W to approximately 2.5″ W, and from approximately ½″ H to approximately ¾″ H. An optional supplementary second support 122 may be located on the same side (convex side) as the second support 121. The supplementary second support 122 may have similar dimensions as the first support 121. The first support 121 and the supplementary first support 122 may be angled or grooved to provide specific seating positions. The profile of one or both the first supports 121, 122 may be rounded, squared-off, angled, etc. In certain embodiments, the supplementary first support 122 may be distal relative to a top of the chair when compared with the first support 121. Additional supports may be provided along the length of the first backrest support arc 115 and the second backrest support arc 117. The seat component 103 may pass between the one or more of the second supports 121, 122.

In certain embodiments, the second support 121 is proximal to the one or more backrest slats 113 as compared to the first support 119. The spacing between the first support 119 and the second support 121 may be varied to alter the seating position of the chair assembly 101. Use of multiple first supports 119 and/or multiple second supports 121 may also allow for various seating positions. The second support 121 may be an integral support member for both lower and upper seating positions to lock lower right and left seating arc supports into desired positions by interplay of upward and downward forces exerted on lower seating arcs.

The backrest component 105 and/or the seat component 103 may have an end bar 123. The end bar 123 may cross between one or more of the first seat support arc 109 and the second seat support arc 111, or the first backrest support arc 115 and the second backrest support arc 117 for additional structural support. Preferably, the end bar 123 may be located proximal to an end of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117, when the chair is in an assembled position. In certain embodiments, the end bar 123 may be located at an opposite end of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117 as the one or more seat slats 107 or the one or more backrest slats 113. The end bar 123 may be round, flattened, rectangular, square, etc. in shape and may be coupled to one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117 by fasteners. The end bar 123 may include one or more holes, similar to those described for the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117.

The ends of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117 that contact the ground in an assembled position may be widened to provide additional stability and/or prevent sinking into soft ground or sand. One or more end caps may be coupled to one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117.

In certain embodiments, an extra slat may be located on the backrest component 105. The extra slat may provide for storage. For example, a bag may fit within the space created by the extra slat. The storage may be webbing, a strap, a slat, or other similar device to create a completely or partially contained space.

The chair assembly 101 may be assembled by one or more users. In preferred embodiments, the chair is assembled by a single user. To assemble the chair, a user may hold the backrest component 105 in a relatively upright position. A relatively upright position may be between approximately 30 to approximately 90 degrees from horizontal, more preferably between approximately 60 to approximately 90 degrees from horizontal. The user may then insert the seat component 103 between the first support 119 and the second support 121. In a preferred embodiment, one or more of the seat slats 107 may contact the first backrest support arc 115 and the second backrest support arc 117. In certain embodiments, a user may insert the seat component 103 through an opening created by either the first support 119 or the one or more backrest slats 113 and the second support 121 to create a variable, desired seating position. The cooperation between the seat component 103 and the backrest component 105 may create a structurally secure seat for the user.

To disassemble the chair, a user would remove the seat component 103 from contact with the first backrest support arc 115 and the second backrest support arc 117 and slide it out of the backrest component 105.

FIG. 9 is a perspective view of the collapsible chair assembly of FIG. 1 in a nested position, according to one embodiment. For storage and transport, embodiments of the chair assembly 101 may nest within one another. When in a nested position, the chairs may be stacked vertically or horizontally. The nested position may minimize space taken up by the chair. The seat component 103 may be sized to fit within the backrest component 105. Furthermore, the arcs of the seat component 103 and the backrest component 105 may be complementary and/or substantially similar such that the seat component 103 is hidden within the backrest component 105 when in a nested position. The first support 119 and the second support 121 may provide a mechanism for securing the seat component 103 within the backrest component 105. The separation and position of the first support 119 and the second support 121 may provide for limited movement of the components relative to one another.

In alternate embodiments, the dimensions and role of the seat component 103 and the backrest component 105 may be reversed, such that the backrest component 105 nests within the seat component 103.

Transport and storage may be facilitated by the nesting of the components. A single user may carry the nested device. The arc of the nested device may allow for easier and more comfortable carrying as the nested device may at least partially wrap around the user's body when carried by one or more of the arc components.

As noted above, in certain embodiments, one or more components may be made of materials such as injection molded plastics. Certain embodiments may use recycled, recyclable, sustainable, or other materials. Certain embodiments may use lightweight materials to reduce the overall weight of the chair assembly 101. In certain embodiments, one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117 may be made of plastic or other similar materials, such as injection molded plastic. Use of plastic may reduce overall weight of the chair assembly 101. Strength and/or flexibility of the chair assembly 101 may also be increased. Additionally, different arcs may be possible using plastic or other similar materials. For example, a greater arc may be structurally achieved using injection molded plastic than possible with wood. An additional benefit of using plastic for larger arcs of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117 may be reduced waste. To create increasing arcs, a larger starting piece of wood must be used. This may create additional waste to cut out the more pronounced arc. In certain embodiments, the holes may facilitate carrying the chair when it is collapsed or assembled.

In certain embodiment, a handle may be provided in a top slat of one or more of the backrest slats and the seat slats. The handle may provide for easier carrying and moving of the chair.

In certain embodiments, such as certain injection molded embodiments, the cross section of any injection molded version with holes or no holes may have an “H” section in cross section. In certain injection molding processes, thin wall sections may allow for rapid cooling of the parts. Therefore, to obtain strength, the sections may be “T”-shaped or “H”-shaped to provide lateral strength. In certain embodiments, wall thickness may be between approximately ⅛″ and approximately 1″, more preferably approximately ¼″. In an embodiment of an arc support member with no holes, the “T” section may be evident along the outer perimeter of the arc member, which is between the outer edge and the web of the member. In an arc member with holes or slots or a combination of the two, the “H” section may be formed by the section along the perimeter of the arc member and the outer diameter of the holes or ovals and the web between the two surfaces. The low resistance of two plastic surfaces may facilitate ease of assembly and disassembly of the two component pieces of the chair during set up and disassembly into its nested position.

To further reduce the weight of the chair when using wood or other materials, one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117 may have one or more holes. The holes may have any shape, such as slots. In certain embodiments, there may be no holes in the arc members. The one or more holes may not be related to securing components of the chair assembly together and/or attaching accessories or other objects to the chair assembly. The one or more holes may not be holes for nails, screws, bolts, or other fasteners. The one or more holes may pass partially or completely through one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117. The one or more holes may be circular, ovoid, square, rectangular, or any other shape. The shape may vary based on the desired aesthetic. Preferably, the one or more holes reduce weight of one or more of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117, but do not have a substantial impact on strength and/or flexibility of one or more of the one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117. In certain embodiments, the one or more holes may have a minimum diameter of greater than approximately ½″, more preferable greater than approximately ¾″, more preferable greater than approximately 1″, more preferable greater than approximately 1.5″, more preferable greater than approximately 2″, more preferable greater than approximately 2.5″, and more preferably greater than 3″. In certain embodiments, the one or more holes may occupy greater than approximately 25%, more preferably greater than 30%, more preferably greater than 40%, more preferably greater than approximately 50%, more preferably greater than 60%, and more preferably greater than 75% of the width of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117. In certain embodiments, the one or more holes may occupy more than approximately 25%, more preferably more than 35%, more preferably more than 50%, more preferably more than 60% of the surface area of one or more of first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and/or the second backrest support arc 117.

FIGS. 10A-10E are side views of exemplary opening locations, according to certain embodiments. The number and location of the one or more holes may vary. The one or more holes may be spaced at various distances apart, including at varying distances along one or more of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117. In certain embodiments, there may be between approximately 1 and 20 holes, more preferably, between approximately 2 and 15 holes, and more preferably between approximately 3 and 12 holes. Embodiments with no holes may also be provided. Various patterns and combinations may be used. In certain embodiments, the one or more holes may be circles and may be evenly spaced along the length of one or more of one or more of the first seat support arc 109, the second seat support arc 111, the first backrest support arc 115, and the second backrest support arc 117.

FIGS. 11A-11F are perspective views showing exemplary seating positions, according to certain embodiments. Certain embodiments may provide for various seating positions. A user may select which position to place the chair. The seating positions may be continuous between a minimum and maximum angular limit or may have discrete positions between a minimum and maximum angular limit.

FIG. 12 is a perspective view showing multiple chair assemblies coupled to form a base, such as for a tabletop, counter, etc., according to one embodiment. In certain embodiments, no hardware and/or hinges are required to form the base. Connection of a table base configuration may require a pin and/or clip between lower legs and fronts of seating arcs where these members meet. A table top configuration may require a pin and/or clip connection as well. The two chairs may be offset, such that ends of the arc support members overlap. A connection may be made between corresponding ends to secure the assembly in place.

FIG. 13 is a perspective view of an exemplary chair assembly with rocker arcs and arm rests, according to certain embodiments.

In certain embodiments, one or more arm rests 151 may be positioned on the chair assembly 101. The one or more arm rests 151 may be on any portion of the chair assembly 101, but preferably may be located on the first backrest support arc 115 and/or the second backrest support arc 117. In certain embodiments, the one or more arm rests 151 may be located on an outside surface of each seat back arc 115, 117. In certain embodiments, the one or more arm rests 151 may be rotatable, such as rotatable around a fixed end 153. The fixed end 153 may be fixed in various ways, such as use of a pin 155. One or more holes, slots, or openings 157 may be located in the one or more armrests 151. In certain embodiments, the one or more armrests may be solid. The one or more holes, slots, or openings 157 may be of any size or shape, such as described previously for those holes, slots, or openings 118 on other components of the chair assembly 101. One or more flat surfaces 159 may be coupled to the one or more armrests 151. The one or more flat surfaces 159 may be coupled to the one or more armrests 151 by any means, such as, but not limited to, adhesive, screw, nuts and bolts, nails, compression fit, joints, etc. The one or more flat surfaces 159 may provide additional room for a user to place an arm, space to hold one or more items, or room for other activities. The shape and dimensions of the one or more flat surfaces 159 may vary depending on particular uses. In certain embodiments, the one or more flat surfaces 159 may not extend past the outside edge of the seat back arcs 115, 117 to allow for rotation of the one or more arm rests 151.

FIG. 14 is a detail of an exemplary arm rest 151 in an upright position, according to certain embodiments. The one or more armrests 151 may be stored in an upright position for storage or when not needed by a user. In certain embodiments, the one or more holes, slots, or openings 157 may align in an upright position with one or more holes, slots, or openings 118 on the seat back arcs 115, 117. In addition, the one or more armrests 151 may be constructed such that they are in vertical position and alignment with the seat back arcs 115, 117 when not in use. A user may pivot the one or more armrests 151 downward when desired. Thereby, the chair assembly 101 can be used with or without armrests 151.

FIG. 13 also shows one or more rocker arcs 161. By addition of two or more arc members 161 of similar curvature, the chair assembly 101 can be made into a rocking chair. Making a curvature similar to the seat or back arc may maintain a pleasing aesthetic form for the chair assembly 101. The chair assembly 101 may be easily converted to a rocking chair. Two or more rocker arc members 161 may be attached to lower ends of the seat back arcs 115, 117 and/or the seat support arcs 109, 111. In certain embodiments, a first rocker arc 163 may be coupled to a lower end of the first seat support arc 109 and the lower end of the first seat back arc 115. A second rocker arc 165 may be coupled to a lower end of the second seat support arc 111 and the lower end of the second seat back arc 117. The rocker arcs 163, 165 can be temporarily or permanently attached by glue, screws, cotter pins, pin and slot capture or any number of means well known in the art for attachment. One embodiment may include use of a pin 167 at each attachment point. The pin 167 may pass through one or more holes, slots, or openings 169 in the rocker arcs 163, 165. In certain embodiments, the rocker arcs 161 may be solid. The pins may pass through corresponding holes, slots, or openings 118 on the seat back arcs 115, 117 and/or the seat support arcs 109, 111. Certain embodiments may also include threaded inserts and wing nuts.

Arm rests and rocker rails are envisioned as attachments that may allow for increased utility and comfort of the chair. Attachments of these members may be by bolts and nuts, quick pin attachments, or threaded inserts which serve to attach both arm rests 151 and rocker arcs 161 to the assembled chair assembly 101. Attachment of the rocker rails converts the chair into a rocking chair thereby increasing its multifaceted utility and comfort.

Various systems and methods may be used to couple components of the system together. Any of the cross members, such as seat slats 107, backrest slats 113, and/or supports 119, 120, 121, 122 may be attached to the arc members 109, 111, 115, 117 by any of many mechanisms known in the art, such as glue, nails, screws, etc.

One contemplated embodiment may use a seat slat fastener mechanism including a clip and slot capture feature that permits quick and/or tool-less assembly of the chair assembly. FIG. 15 is a perspective view of an exemplary clip 171 that may interact with a slot 173 in a slat 175, as shown in FIGS. 17A-17B. FIG. 16 is a perspective view of an exemplary stand-off 177 that may be used to couple components.

The seat slat fastener mechanism may be associated with the clip 171. The clip 171 may be a bi-directional flexing arm capture locking cap. FIG. 15 shows a particular configuration. In the displayed embodiment, a rectangular base 179 may be used. Other shapes and various sizes may be used as well. A stem 181 may protrude from the base 179, preferably off a center of the base 179. The stem 181 may be bifurcated into a first portion 183 and a second portion 185. The bifurcation may extend some or all of the axial length of the stem 181. One or more tabs 187, 189 may protrude from a surface of the stem 181. In certain embodiments, at least a portion of the one or more tabs 187, 189 may extend outside the footprint of the base 179. In certain embodiments, a first tab 187 may extend in a direction substantially opposite of a second tab 189, such that the tabs are bi-directional. A groove 191 may separate the first tab 187 and the second tab 189. In certain embodiments, the stem 181 may not be bifurcated, but instead, the stem may be flexible to allow for flexing of the one or more tabs 187, 189 in opposite directions during coupling of one or more slats. The one or more tabs 187, 189 may have a barbed configuration such that upon initial contact with a slot 173, the stem flexes to permit entry of the one or more tabs 187, 189 into the slot 173, and once secure the thicker portion of the one or more tabs 187, 189 catches on an outer surface of the slot 173 to secure the slat 175 to the clip 171. The slat 175 may be removed by applying pressure to the one or more tabs 187, 189 until the thicker portion of the one or more tabs 187, 189 are within the opening of the slot 173 and withdrawing the one or more tabs 187, 189 through the slot 173.

Use of one or more clips 171 along the length of the of the arc members 109, 111, 115, 117 may permit attachment of the seat slats 107, backrest slats 113, and/or supports 119, 120, 121, 122. The clips 171 may be integral to the arc members 109, 111, 115, 117, or may be coupled to the arc members 109, 111, 115, 117.

FIG. 16 shows a stand-off 195, which may be used as an alternative to the clip 171. The stand-off 195 may be a bi-directional flexing arm capture locking cap. FIG. 16 shows a particular configuration. In the displayed embodiment, a base 199 may be used. The base 199 may have rounded edges 203 and/or may include a cutout 205. One or more sides of the base 199 may include depressed areas 211. Two or more stems 201 may protrude from the base 199, preferably off a center of the base 179. One or more tabs 207, 209 may protrude from a surface of the stem 201. In certain embodiments, a first tab 207 may extend in a direction substantially opposite of a second tab 209. The stem 201 may be flexible to allow for flexing of the one or more tabs 207, 209 in opposite directions during coupling of one or more slats 175. The one or more tabs 207, 209 may have a barbed configuration such that upon initial contact with a slot 173, the stems 201 may flex to permit entry of the one or more tabs 207, 209 into the slot 173, and once secure the thicker portion of the one or more tabs 207, 209 catches on an outer surface of the slot 173 to secure the slat 175 to the stand-off 195. The slat 175 may be removed by applying pressure to the one or more tabs 207, 209 until the thicker portion of the one or more tabs 207, 209 are within the opening of the slot 173 and withdrawing the one or more tabs 207, 209 through the slot 173.

Use of one or more stand-off 195 along the length of the of the arc members 109, 111, 115, 117 may permit attachment of the seat slats 107, backrest slats 113, and/or supports 119, 120, 121, 122. The stand-off 195 may be integral to the arc members 109, 111, 115, 117, or may be coupled to the arc members 109, 111, 115, 117.

FIG. 17A shows a top view of a slat 175 with one or more slots 173. The one or more slots 173 may be sized and configured to provide a secure fit with one or clip 171 on arc members 109, 111, 115, 117. Each end of the seat slat can incorporate complimentary shaped slots 173 that when in use are positioned over the tabs in the arc members 109, 111, 115, 117. Downward pressure may lock the members together as the flexing tabs are initially compressed and then spring apart to grip the structures together. The flexing arms of the locking mechanism can be part of the arc rail, part of the seat slats, or even a totally separate structure that is inserted to lock the seat slats to the arc rail. In certain embodiments, the clips 171 may be located on the slats 175 and the slots 173 may be located on the arc members 109, 111, 115, 117. These systems and methods may allow for simple and secure assembly of seat slats 175 and arc members 109, 111, 115, 117. The locking clip 171 can be of metal or wood, but it is preferably made of plastic. Acetol plastic (brand name DELRIN, CELCON) is one type of plastic preferred for certain embodiments.

FIG. 17B shows an exemplary underside of a slat 175, according to one embodiment. Various patterns, such as X-shaped patterns 193 may be cut and/or molded into the underside to provide additional strength and/or weight reduction. The patterns 193 may be raised patterns, relief, cutouts, etc.

FIGS. 18A-18B are views of an exemplary rail with a groove, according to certain embodiments. The groove, when coupled with a complementary pin system, may provide a slide and nest feature for the chair assembly. In certain embodiments, the chair assembly may be quickly transformed from a space saving or stored nested position to an expanded chair assembly.

FIG. 18A shows a side view of an arc member 221, which may be a seat support arc and/or a backrest support arc. FIG. 18B is a top view of the arc member 221. The arc member 221 may have one or more holes, slots, or openings 118 along its length. Slat cutouts 223 for various slats (not shown) may be included along the length of the arc member 221. Clip cutouts 225 for various clips (not shown) may be included along the length of the arc member 221. A groove 227 may be included in the arc member 221. The groove 227 may have an opening portion 229 to allow a pin to enter the groove 227, a channel portion 231 to allow the pin to slid through the groove 227, and a terminal portion 233 to stop movement of the pin in the groove 227. If the arc member 221 of FIG. 18A is a left side member, the right side member would be a mirror image.

The pin and groove system may allow the chair assembly to be reconfigured from a nested position whereby multiple seat support arc members and multiple backrest support arc members may slide relative to one another. Certain embodiments may include grooves on the support arc members and pins on the backrest support arc member, and vice versa. Preferably the groove 227 may exist on inner faces of each backrest support arc member and the pin may exist on the outside of the seat support arc member; however, one of skill in the art would recognize the groove 227 could also be part of the seat support arc members and the pin part of the inside of the backrest support arc members.

As an example, from a nested position, i.e., from a position where the inner seat support arc member is slid and nested between the outer backrest support arc assembly, the chair assembly may be brought to a seating position by lifting the outer backrest support arc assembly, allowing the inner seat support arc assembly to slide downward. The pins may move from a terminal portion 233 of the groove 227 through the channel portion 231 of the groove 227, to the opening portion 229 of the groove. This may allow the inner seat support arc assembly to pivot outward and extend to a functional seating position. This feature may allow smooth and simple, single handed operation from nested to seating positions utilizing no hardware.

For some embodiments, the pins on the arc members may be approximately ½″ to approximately 2″ in diameter, preferably approximately ¾″ to approximately 1¾″ diameter, and most preferably approximately 1″ to approximately 1¾″ diameter. The grooves on the arc members may be from approximately ¾″ to approximately 2″ in width, preferably approximately 1″ to approximately 2″ in width, and most preferably approximately 1¼″ to approximately 2″ in width. One of skill in the art can immediately appreciate that using metal or plastic pins may permit smaller pins and arc grooves.

Various methods of manufacture may be utilized for wood and/or plastic chair assemblies.

For wood or plywood construction, wood components, such as arc members and slats, may be efficiently in various ways as described herein. One of skill in the art would immediately recognize other means of manufacture.

1. The configuration of the arc/rail to be produced may be mechanically entered into a CAD (computer aided design) program, which may prescribe the arc/rail curvature and length as well as desired holes and/or slots and grooves. The data from for the program may be taken from mechanical drawings and/or from existing prototypes. The CAD program may then be converted to a CAM (computer aided manufacturing) program, which may control a CNC (computer numerical control) machine that cuts and shapes the arc/rails.

2. Panels of solid dimensional lumber may be edge glued together to form a panel of given dimensions to yield arcs/rails with a minimum of waste from the glued panel. One preferred glue is TITEBOND III, which conforms to ANSI Type 1 water resistance. Woods may be selected from cypress, pine, oak, sassafras, teak, mahogany, cedar, ash or other domestic or imported hard or softwoods, and combinations thereof. Thickness may vary from between 0.25 and 2.5 inches, preferably 0.5 to 2 inches, and most preferably 1 to 1.5 inches.

3. Arc/rails curves and internal holes, slots and grooves may be cut with the use of a CNC automated (router) machine or 3-axis CNC Mill or any other suitable automated cutting machine.

4. Holes and/or slots edges may be radiused and the arc/rail surfaces may be sanded smooth.

The cutting of arc/rails as described above may also be applied to sheet plastic materials or aluminum.

For plastic construction, injection molding may be utilized for producing chair assembly components. Material for a given part may be fed into a heated barrel, mixed and fed into a mold cavity where it cools and hardens to the configuration of the cavity. Molds may be made from aluminum or steel and precision machined to form the features of individual chair components.

Material for injection molded components may be structural foam (polypropelene with a foaming agent) and/or glass filled resin. Some embodiments of chair components may also include carbon fiber lay up or compression molding.

Certain embodiments may be assembled during manufacturing. In alternative embodiments, some or all components may be assembled by a consumer.

Certain exemplary embodiments may be directed to a collapsible chair assembly comprising: a seat component comprising a first seat support arc, a second seat support arc, and one or more seat slats spanning between the first seat support arc and the second seat support arc; one or more holes in at least one of the first seat support arc and the second seat support arc; and the seat component capable of passing through an opening created by at least one first support and at least one second support in a backrest component and being secured in position by contact with the at least one first support and the at least one second support.

Certain exemplary embodiments may be directed to a collapsible chair assembly comprising: a backrest component comprising at least one first support, at least one second support, a first backrest support arc, a second backrest support arc, and one or more backrest slats spanning between the first backrest support arc and the second backrest support arc; one or more holes in at least one of the first backrest support arc and the second backrest support arc; and the backrest component capable of receiving a seat component passing through an opening created by the at least one first support and the at least one second support and secured in position by contact with the at least one first support and the at least one second support.

Certain exemplary embodiments may be directed to a collapsible chair assembly comprising: a seat component comprising a first seat support arc, a second seat support arc, and one or more seat slats spanning between the first seat support arc and the second seat support arc; a backrest component comprising at least one first support, at least one second support, a first backrest support arc, a second backrest support arc, and one or more backrest slats spanning between the first backrest support arc and the second backrest support arc; and the seat component passing through an opening created by the at least one first support and the at least one second support and secured in position by contact with the at least one first support and the at least one second support.

Although the foregoing description is directed to the preferred embodiments of the invention, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the invention. Moreover, features described in connection with one embodiment of the invention may be used in conjunction with other embodiments, even if not explicitly stated above. 

What is claimed is:
 1. A collapsible chair assembly comprising: a seat component comprising a first seat support arc, a second seat support arc, and one or more seat slats spanning between the first seat support arc and the second seat support arc; a backrest component comprising at least one first support, at least one second support, a first backrest support arc, a second backrest support arc, and one or more backrest slats spanning between the first backrest support arc and the second backrest support arc; one or more holes in at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc; and the seat component passing through an opening created by the at least one first support and the at least one second support and secured in position by contact with the at least one first support and the at least one second support.
 2. The assembly of claim 1, wherein the one or more holes are circular.
 3. The assembly of claim 1, wherein the one or more holes are evenly spaced along the length of at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc.
 4. The assembly of claim 1, wherein the one or more holes occupy more than approximately 50% of the width of the at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc.
 5. The assembly of claim 1, wherein the one or more holes occupy more than 25% of the surface area of at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc.
 6. The assembly of claim 1, wherein at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc are made of injection molded plastic.
 7. The assembly of claim 1, further comprising a second chair assembly interlocked with the chair assembly to create a base for a table.
 8. The assembly of claim 1, wherein an arc of at least one of at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc is greater than approximately 2″ deflection over a length of approximately 42″.
 9. The assembly of claim 1, further comprising one or more armrests pivotably mounted to the first backrest support arc or the second backrest support arc.
 10. The assembly of claim 1, further comprising a first rocker arc between the first seat support arc and the first backrest support arc and a second rocker arc between the second seat support arc and the second backrest support arc.
 11. The assembly of claim 1, further comprising one or more clips with bi-directional barbed tabs for securing the one or more seat slats to the first seat support arc or the second seat support arc or for securing the one or more backrest slats to the first backrest support arc or the second backrest support arc.
 12. The assembly of claim 1, further comprising a groove with one or more first seat support arc, the second seat support arc, the first backrest support arc, or the second backrest support arc and a complementary pin in one or more first seat support arc, the second seat support arc, the first backrest support arc, or the second backrest support arc, wherein the complementary pin slides in the groove to move the assembly from a nested position to a seating position.
 13. A method for assembling a collapsible chair assembly, the method comprising: providing a seat component comprising a first seat support arc, a second seat support arc, and one or more seat slats spanning between the first seat support arc and the second seat support arc; providing a backrest component comprising at least one first support, at least one second support, a first backrest support arc, a second backrest support arc, and one or more backrest slats spanning between the first backrest support arc and the second backrest support arc, and one or more holes in at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc; and inserting the seat component through an opening created by either the at least one first support or the one or more backrest slats and the at least one second support to create a variable, desired seating position.
 14. The method of claim 13, wherein the one or more holes occupy more than approximately 50% of the width of the at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc.
 15. The method of claim 13, wherein the one or more holes occupy more than 25% of the surface area of at least one of the first seat support arc, the second seat support arc, the first backrest support arc, and the second backrest support arc.
 16. The method of claim 13, further comprising interlocking two or more chair assemblies to create a base for a table.
 17. The method of claim 13, further comprising adjusting the backrest by positioning the seat component relative to the backrest component.
 18. The method of claim 13, further comprising disassembling the collapsible chair assembly by removing the seat component from the backrest component.
 19. The method of claim 13, further comprising nesting the seat component within the backrest component.
 20. The method of claim 13, further comprising sliding a complementary pin in one or more first seat support arc, the second seat support arc, the first backrest support arc, or the second backrest support arc in a groove with one or more first seat support arc, the second seat support arc, the first backrest support arc, or the second backrest support arc to move the assembly from a nested position to a seating position. 